Multilayer cover nonwoven for a vehicle interior lining, interior lining with such a cover nonwoven and method for producing such a cover nonwoven

Abstract

The invention refers to a cover nonwoven for an interior lining for a vehicle, comprising a nonwoven fabric consisting of at least two nonwoven layers, a first nonwoven layer and a second nonwoven layer, wherein a first outer surface of the nonwoven fabric is formed by a surface of the first nonwoven layer and a second outer surface of the nonwoven fabric is formed by a surface of the second nonwoven layer, and wherein the first nonwoven layer and the second nonwoven layer are inseparably bonded on the entire surface.According to the invention, the first nonwoven layer is formed of a rough polypropylene spunlaced nonwoven and the second nonwoven layer is formed of a dense polypropylene spun-bonded nonwoven, wherein the first outer surface of the nonwoven fabric is suitable for the application of a pressure-sensitive adhesive, and wherein the second outer surface of the nonwoven fabric has hydrophobic properties.

The invention claimed is: 
     
       1. A method of manufacturing a cover nonwoven for an interior lining for a vehicle the method comprising:
 forming a nonwoven fabric having at least two nonwoven layers, the at least two nonwoven layers comprising a first nonwoven layer and a second nonwoven layer, 
 
       wherein a first outer surface of said nonwoven fabric is formed by a surface of said first nonwoven layer and a second outer surface of said nonwoven fabric is formed by a surface of said second nonwoven layer;
 wherein the first outer surface of the nonwoven fabric is suitable for applying a pressure-sensitive adhesive, and 
 wherein the second outer surface of the nonwoven fabric has hydrophobic properties; and 
 inseparably bonding the first nonwoven layer and the second nonwoven layer over the entire surface, 
 wherein the first nonwoven layer is formed from a rough polypropylene spunlaced nonwoven, 
 wherein the first nonwoven layer is rough due to a ratio (p/v) of an entangling pressure (p) applied to solidify the first nonwoven layer and a production speed (v) where the ratio does not exceed a value of 9.0 bar/(m/min), 
 wherein the second nonwoven layer is formed from a dense polypropylene spun-bonded nonwoven, 
 wherein the second nonwoven layer is dense by virtue of having an air permeability of at most 400 l/(m 2 ·s) at a pressure difference of 1 mbar between the first outer surface of the second nonwoven layer and the second outer surface of the second nonwoven layer. 
 
     
     
       2. The method according to  claim 1 , wherein the ratio (p/v) is in the range between 6.0 and 8.0 bar/(m/min). 
     
     
       3. The method according to  claim 1 , wherein the second nonwoven layer is solidified by means of a calender, wherein the parameters of calender pressure (q), calender temperature (T) and production speed (v) are selected during the solidification of the second nonwoven layer such that a ratio (q·T/v) does not fall below a value of 60 K·MPa·s. 
     
     
       4. The method according to  claim 3 , wherein the ratio (q·T/v) is in the range between 70 and 100 K·MPa·s. 
     
     
       5. The method according to  claim 3 , wherein the first nonwoven layer is thermally laminated onto the second nonwoven layer with the aid of a calender, or wherein the first nonwoven layer and the second nonwoven layer are joined by means of hydroentanglement. 
     
     
       6. The method according to  claim 3 , wherein the first nonwoven layer or the second nonwoven layer has an abrasion resistance up to the destruction of the fibrous structure of the first nonwoven layer according to the Martindale method of at most 2,000 intervals at a weight load of 12 kN. 
     
     
       7. The method according to  claim 3 , wherein:
 the second nonwoven layer has a weight per unit area between 25 g/m 2  and 40 g/m 2 ; or 
 the second nonwoven layer comprises at least one melt-blown intermediate layer; or 
 the second nonwoven layer has a thickness of 0.1 mm to 0.8 mm; or 
 the second nonwoven layer has a water resistance of at least 20 cmH 2 O.